Technique to detect motor leakage flux anomalies

ABSTRACT

A signal processor is configured to receive signaling containing information about a sensed sinusoidal waveform of magnetic flux caused by a current flowing in a winding of a motor having a component of distortion caused at least in part by a magnetic flux created by the current flowing, and also about a pure sinusoidal waveform of a sensed fundamental frequency of the magnetic flux; and determine corresponding signaling containing information about anomalies in the motor that depends on a relationship between the sensed sinusoidal waveform and the pure sinusoid waveform, based upon the signaling received. The signaling may be sensed and provided by a motor magnetic flux sensor attached externally to the motor frame.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation under 35 U.S.C. § 120 of co-pending U.S. patent application Ser. No. 15/648,855 filed on Jul. 13, 2017 and entitled “TECHNIQUE TO DETECT MOTOR LEAKAGE FLUX ANOMALIES.” U.S. Patent Application, including any appendices or attachments thereof, is incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This application relates to a technique for detecting motor leakage flux anomalies; and more particularly to technique for detecting motor leakage flux anomalies in a motor.

2. Brief Description of Related Art

The following techniques are known in the art:

EP 1046044 B1 discloses a technique based upon using a differential current transformer to sense ground leakage current, and processes the signal to allow easy alarm trips, e.g., using a current transformer (amps) sensor placed in series with the power conductors feeding the motor. The EP 1046044 B1 technique does not track the motor load via the leakage flux and a flux sensor to sense changes in the load to indicate anomalies in operation before catastrophic damage occurs.

U.S. Pat. No. 5,680,025 discloses a technique that uses a flux coil to sense motor load and flux signals, but does not disclose the ability to cancel out sinusoids.

U.S. Pat. No. 6,308,140 B1 discloses a technique that senses motor current, not flux, and uses the motor current to detect broken rotor bars in the motor. U.S. Pat. No. 7,880,473 discloses a technique for non-invasive monitoring and diagnosis of a motor by measuring external flex density by comparing a combined value of magnetic field values measured at various points external to the motor to an expected combined value to determine if a fault is present in the motor.

No technique are known in the art for sensing motor flux non-invasively, and cancelling out sinusoid waveforms and using the resultant signal for baselining and trending, thereby allowing for accurate comparing and diagnosis for the purpose of indicating pending motor failure with an accurate diagnosis.

In view of this, there is a need in the industry for a better way for detecting electrical and mechanical faults in a motor driving a pump.

SUMMARY OF THE INVENTION

In summary, and in contrast to the prior art techniques set forth above, the present invention provides a new and unique technique for detecting motor leakage flux anomalies, which is based upon attached a magnetic flux sensor to the motor frame. In particular, a motor leakage flux detector, e.g., including a fluxgate device, may be attached to the motor's outer frame.

Specific Embodiments Of The Present Invention

According to some embodiments, the present invention may take the form of apparatus, e.g., such as a controller for a motor driving a pump, featuring: a

signal processor configured to

-   -   receive signaling containing information about a sensed         sinusoidal waveform of magnetic flux caused by a current flowing         in a winding of a motor having a component of distortion caused         at least in part by a magnetic flux created by the current         flowing, and also about a pure sinusoidal waveform of a sensed         fundamental frequency of the magnetic flux; and     -   determine corresponding signaling containing information about         anomalies in the motor that depends on a relationship between         the sensed sinusoidal waveform and the pure sinusoid waveform,         based upon the signaling received.

The present invention may also include one or more of the following features:

The signaling may be sensed and provided by a motor magnetic flux sensor arranged in relation to the winding.

The apparatus may include the motor magnetic flux sensor.

The apparatus may include the motor having a motor frame; and the motor magnetic flux sensor is attached to the motor frame, including where the motor frame is an outer motor frame and the motor magnetic flux sensor is a leakage magnetic flux sensor.

The sensed sinusoidal waveform has a sinewave component with distortion riding on the sensed sinusoidal waveform.

The relationship may be a difference between the sinusoidal waveform and the pure sinusoidal waveform of the fundamental frequency of the magnetic flux, that results in a non-sinusoid magnetic flux waveform of magnetic flux distortion.

The signal processor may be configured to store and record in a memory module baseline signaling containing information about a baseline difference for subsequent comparison with a subsequent difference determined at a later point in time.

The magnetic flux distortion may contain information about either mechanical or electrical pending failure.

The mechanical failure may include vibration caused by a misalignment, an out of balance condition, or one or more failing bearings.

The electrical failure may include e.g. a partially shorted winding, a broken rotor bar, an eccentric air gap, or damaged laminations.

The signal processor may be configured to process associated signaling containing information about the non-sinusoid magnetic flux waveform to determine mechanical or electrical pending failure, e.g., by using one or more of the following techniques:

-   -   implementing a dynamically boosted gain technique on the         associated signaling to amplify minor flux distortions for         further analysis; or     -   implementing a fundamental sinewave cancellation technique that         allows for a motor's non sinusoidal flux “signature” to be         recorded/stored during a period of known proper operation for         establishing a motor's non sinusoidal flux “signature” baseline,         that allows for a subsequent motor's non sinusoidal flux         “signature” to be recorded/stored during a subsequent period of         operation, and that also allows a comparison analysis of the         motor's non sinusoidal flux “signature” baseline and the         subsequent motor's non sinusoidal flux “signature” to determine         one or more minimum deviations over time regarding corresponding         wave shapes in both amplitude and frequency; or     -   establishing an alarm threshold for a deviation value that         indicates an abnormal condition, including where the abnormal         condition is not a condition to cause immediate damage, so a         motor system may be investigated for a potential abnormal         condition while the motor system is running, and not stopped due         to a damaging fault.

The signal processor may be configured to process associated signaling containing information about the non-sinusoid magnetic flux waveform performing spectral analysis, including using Fast Fourier Transform analysis, to determine anomalies based upon a comparison a baseline sinusoidal waveform determined during normal operation at a first point in time and a subsequent sinusoidal waveform determined at a second and later point in time.

The signaling received at the first point in time may contain information about the baseline sinusoidal waveform of the current flowing in the winding of the motor having the distortion caused at least in part by the magnetic flux created by the current flowing during the normal operation, and the signaling received at the second point in time contains information about the subsequent sinusoidal waveform of the current flowing in the winding of the motor having the distortion caused at least in part by the magnetic flux created by the current flowing at second and later point in time.

The motor may be an AC induction motor configured to draw a pure sinusoid waveform of current when supplied with a sinusoid AC voltage.

The signal processor may be configured to decompose the signaling received to determine first signaling containing information about the sinusoidal waveform of the current flowing in the winding of the motor, and determine second signaling containing information about the distortion caused at least in part by the magnetic flux created by the current flowing.

The signaling received may include first signaling containing information about the sinusoidal waveform of the current flowing in the winding of the motor, and includes second signaling containing information about the distortion caused at least in part by the magnetic flux created by the current flowing.

The signal processor may be configured to provide the corresponding signaling determined containing information about the anomalies in the motor.

The corresponding signaling determined may contain information about the mechanical failure, including the vibration caused by the misalignment, the out of balance condition, or the one or more failing bearings.

The corresponding signaling determined may contain information about the electrical failure, including the partially shorted winding, the broken rotor bar, the eccentric air gap, or the damaged laminations.

The signal processor may be configured to provide the corresponding signaling for further processing, including as control signaling.

The apparatus may include, or takes the form of, a controller, e.g., having the signal processor.

According to some embodiments, the apparatus may include, or takes the form of, the pump system having the controller with the signal processor for implementing the aforementioned signal processing functionality. The pump system may include the motor and a pump driven by the motor.

According to some embodiments, the present invention may take the form of a method featuring steps for:

-   -   receiving in a signal processor signaling containing information         about a sensed sinusoidal waveform of magnetic flux caused by a         current flowing in a     -   winding of a motor having a component of distortion caused at         least in part by a magnetic flux created by the current flowing,         and also about a pure sinusoidal waveform of a sensed         fundamental frequency of the magnetic flux; and     -   determining in the signal processor corresponding signaling         containing information about anomalies in the motor that depends         on a relationship between the sensed sinusoidal waveform and the         pure sinusoid waveform based upon the signaling received.

The method may include providing with the signal processor the corresponding signaling for further processing, including as control signaling, as well as one or more of the features set forth herein.

In effect, the present invention provides a new and unique for sensing motor flux non-invasively, and cancelling out sinusoid waveforms and using the resultant signal for baselining and trending, thereby allowing for accurate comparing and diagnosis for the purpose of indicating pending motor failure with an accurate diagnosis.

BRIEF DESCRIPTION OF THE DRAWING

The drawing, not necessarily drawn to scale, includes the following Figures:

FIG. 1 shows a graph of a sine wave function (amplitude vs. time) of a pure sinusoid waveform of current, e.g., which is typically provided to an AC induction motor.

FIG. 2 shows a graph of a waveform (amplitude vs. time) of magnetic flux created by the current flowing in the AC induction motor, e.g., received from a motor magnetic flux sensor attached to an outer frame of the motor, having a sinewave component with distortion riding on the wave shape.

FIG. 3 shows a graph of a non-sinusoidal waveform (amplitude vs. time) of magnetic flux minus the sine wave function by the current flowing in the AC induction motor, e.g., for diagnosing potential motor and/or load problems.

FIG. 4 shows apparatus having a signal processor configured to process signaling received and determine corresponding signaling containing information about anomalies in a motor, e.g., for driving a pump, according to some embodiments of the present invention.

FIG. 5 shows a block diagram of a motor having an outer frame with a motor leakage flux detector arranged thereon, e.g., including a fluxgate device, according to some embodiments of the present invention.

FIG. 6 shows a flowchart of a basic method/algorithm, according to some embodiments of the present invention.

Not every reference numeral is included in every Figure, e.g., so as to reduce clutter in the drawing as a whole.

DETAILED DESCRIPTION OF THE INVENTION The Basic Invention

An AC induction motor like element 20 (FIG. 4), e.g., for driving a pump like element 30 (FIG. 4), is designed to draw a pure sinusoid waveform of current when supplied with a sinusoid AC voltage. For example, see the sine wave function shown in FIG. 1.

This current flowing in the motor's windings (20 c (FIG. 5)) will create a sinusoid of magnetic flux. According to the present invention, for diagnosis of motor and/or load problems, it is imperative to examine the magnetic flux that is not sinusoidal. For example, see the motor flux function shown in FIG. 2.

The waveform in FIG. 2, e.g., received from the motor magnetic flux sensor 20 like element 20 b, has a sinewave component with distortion riding on the wave shape. The flux distortion is the indicating component of anomalies that allow for diagnosis of abnormalities. This flux distortion could indicate either mechanical or electrical pending failure. Examples of mechanical failure are vibration caused by misalignment, out of balance, failing bearings, etc. Examples of electrical failure could also be representative of the motor's windings or rotor developing a pending failure, e.g. partially shorted winding, broken rotor bar, eccentric air gap, damaged laminations, etc.

According to the present invention, the technique herein proposes to sense the fundamental frequency of the magnetic flux, and mathematically subtract the exact same frequency as a pure sinusoid waveform. The signal that remains is the non-sinusoid magnetic flux (see FIG. 3), which can be processed to diagnose potential motor and/or load problems.

Numerous processes can be performed on the resultant signal. For example, one very important technique is a dynamically boosted gain of the resultant signal to allow much improved examination of minor flux distortions. By greatly amplifying these very small signals, improved diagnosis of previously undiscovered anomalies can be performed.

In addition, fundamental sinewave cancellation allows for a motor's non sinusoidal flux “signature” to be recorded (e.g., sensed and stored in a suitable memory module like that forming part of element 10 b) during a period of known proper operation, also called “base lining”. This ability to provide a very detailed comparison to the non-sinusoidal component allows for a more accurate baseline signal to be established during a known good operational period.

By performing a comparison analysis of a questionable signal to the baseline signal recorded, minimum deviation over time regarding wave shape in both amplitude and frequency can be determined. By establishing an alarm threshold for a deviation value that indicates an abnormal condition, but not a condition to cause immediate damage, the user may investigate a potential abnormal condition while the system is running, and not stopped due to a damaging fault.

Lastly, a spectral analysis, e.g. using a Fast Fourier Transform analysis, can easily be performed to indicate anomalies from normal operation.

By using a motor leakage sensor 20 b attached to the outer frame 20 a of the motor 20, one can non-invasively sense motor leakage. By subtracting the known good sinusoidal signal from the motor's non-sinusoidal flux signature, one can record a baseline of a known good working motor. That unique profile can be used to compare against future anomalies to determine pending failure.

By way of further example, embodiments are also envisioned using the addition of current sensors 20 d to sense motor current versus leakage flux sensors, but the same method could be used to trend the motor's current signature and compare future operations. However, adding current sensors 20 d would be a non-invasive solution.

FIG. 4: The Basic Apparatus 10, including a Pump System

FIG. 4 shows apparatus generally indicated as 10 according to some embodiments of the present invention, e.g., including a combination of a signal processor or signal processing module 10 a, other signal processor circuits or components 10 b, the motor 20 and the pump 30.

In operation, the signal processor or signal processor module 10 a may be configured to

-   -   receive signaling containing information about a sensed         sinusoidal waveform of magnetic flux caused by a current flowing         in a winding of a motor having a component of distortion caused         at least in part by a magnetic flux created by the current         flowing, and also about a pure sinusoidal waveform of a sensed         fundamental frequency of the magnetic flux; and     -   determine corresponding signaling containing information about         anomalies in the motor that depends on a relationship between         the sensed sinusoidal waveform and the pure sinusoid waveform,         based upon the signaling received.

By way of example, the functionality of the signal processor 10 a may be implemented using hardware, software, firmware, or a combination thereof. In a typical software implementation, the signal processor or signal processing module 10 a would include one or more microprocessor-based architectures having, e.g., at least one processor or microprocessor, random access memory (RAM) and/or read only memory (ROM), input/output devices and control, and data and address buses connecting the same, and/or at least one input processor and at least one output processor. A person skilled in the art would be able to program such a microcontroller (or microprocessor)-based implementation to perform the functionality described herein without undue experimentation. The scope of the invention is not intended to be limited to any particular implementation using technology either now known or later developed in the future. The scope of the invention is intended to include implementing the functionality of the signal processor as stand-alone processor or processor module, as separate processor or processor modules, as well as some combination thereof.

By way of example, after reading the instant patent application, one skilled in the art would appreciate without undue experimentation how to implement the signal processor 10 a to receive the signaling containing information about the sensed sinusoidal waveform of magnetic flux caused by the current flowing in the winding of the motor having the component of distortion caused at least in part by the magnetic flux created by the current flowing, and also about the pure sinusoidal waveform of the sensed fundamental frequency of the magnetic flux. The implementation may include the signal processor 10 a cooperating, or working in conjunction with, the input/output module forming part of the other component or circuitry forming part of element 10 b.

By way of further example, after reading the instant patent application, one skilled in the art would appreciate without undue experimentation how to implement the signal processor 10 a to determine the corresponding signaling containing information about the anomalies in the motor that depends on the relationship between the sensed sinusoidal waveform and the pure sinusoid waveform, e.g., including mechanical and/or electrical anomalies as set forth herein. By way of example, vibration of the motor and the motor leakage sensor 20 b in relation to the windings of the motor may cause irregularities in the sensed motor flux that may distort the waveform of the magnetic flux sensed by the motor leakage sensor 20 b. The signal processor 10 a may be configured to use the baseline signature analysis to process the non-sinusoidal waveform, e.g., like that shown in FIG. 3, and determine the information about the anomalies in the motor 20 based upon the irregularities in the sensed motor flux that distort the waveform of the magnetic flux sensed by the motor leakage sensor 20 b and caused by the vibration. Similarly, one skilled in the art without undue experimentation would also be able to implement corresponding baseline signature analysis techniques to determine other type or kind of electrical and/or mechanical anomalies in the motor.

It is important to note that the scope of the invention is not intended to be limited to any particular type or kind of electrical and/or mechanical anomaly in the motor determined, and may include anomalies both now known and later developed in the future. In other words, embodiments are envisioned, and the scope of the invention is intended to include, determining other types or kind of anomalies than that set forth herein.

The apparatus 10 may also include one or more other modules, components, etc. generally indicated as 10 b for implementing other functionality associated with the apparatus, but that does not form part of the underlying invention and is not described in detail.

The apparatus may also include the motor 20 having the outer housing 20 a with the motor leakage flux detector 20 b attached thereto, e.g., as shown in FIG. 5. By way of further example, the motor 20 may also include a rotor and stator combination 20 c with windings, the current sensors 20 d, as well as other motor components 20 e that are known in the art.

FIG. 6: The Basic Method

FIG. 6 shows a flow chart 50 of a method/algorithm having steps for determining anomalies in a motor, according to some embodiments of the present invention, e.g., including implementing some combination of steps 50 a, 50 b, 50 c and 50 d. By way of example, the flowchart 50 includes, e.g., a step 50 d for arranging the outer frame 20 a of the motor 20 with the motor leakage flux detector 20 b to sense the sinusoidal waveform of the current flowing in the winding of the motor having the distortion caused at least in part by the magnetic flux created by the current flowing.

The Scope of the Invention

It should be understood that, unless stated otherwise herein, any of the features, characteristics, alternatives or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein. Also, the drawing herein is not drawn to scale.

Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein and thereto without departing from the spirit and scope of the present invention. 

1.-26. (canceled)
 27. An apparatus to detect a motor leakage flux anomaly from a winding of a motor in a frame, the apparatus comprising: a sensor attached to the frame of the motor, wherein the sensor is configured to sense a sinusoidal waveform of magnetic flux caused by a current that flows in the winding of the motor; and a signal processor configured to: receive a signal from the sensor that contains information about the sensed sinusoidal waveform, wherein the sinusoidal waveform has a component of distortion caused at least in part by the magnetic flux created by the current that flows in the winding of the motor; receive another signal that contains information about a pure sinusoidal waveform of a fundamental frequency of the sinusoidal waveform; compare the signal to the other signal; extract a non-sinusoidal magnetic flux waveform of magnetic flux distortion based on the comparison of the signal to the other signal; compare the extracted non-sinusoidal magnetic flux waveform of magnetic flux distortion to a baseline non-sinusoidal magnetic flux waveform signature of the motor recorded during a period of proper operation; and generate a corresponding signal that contains information about anomalies in the motor based on the comparison of the extracted non-sinusoidal magnetic flux waveform of magnetic flux distortion to the baseline non-sinusoidal magnetic flux waveform signature.
 28. The apparatus of claim 27, wherein the sensor is a motor magnetic flux sensor arranged in relation to the winding.
 29. The apparatus of claim 28, wherein the sensor is a leakage magnetic flux sensor.
 30. The apparatus of claim 27, wherein the signal processor is configured to extract the non-sinusoidal magnetic flux waveform of magnetic flux distortion through subtraction of the pure sinusoidal waveform from the sinusoidal waveform of magnetic flux distortion.
 31. The apparatus of claim 27, wherein the signal processor is further configured to determine information about either a mechanical or an electrical pending failure of a component of the motor based on the magnetic flux distortion.
 32. The apparatus of claim 31, wherein the mechanical failure includes vibration caused by a misalignment, an out of balance condition, or one or more failing bearings, and the electrical failure includes a partially shorted winding, a broken rotor bar, an eccentric air gap, or damaged laminations.
 33. A system to detect a pending failure of a component of a motor, the system comprising: a flux detector attached to a frame of the motor in relation to a winding of the motor, wherein the flux detector is configured to sense a sinusoidal waveform of magnetic flux caused by a current that flows in the winding of the motor; and a controller coupled to the flux detector, the controller comprising: a memory configured to store a baseline non-sinusoidal magnetic flux waveform signature of the motor recorded during a period of proper operation; and a signal processor configured to: receive a signal from the flux detector that contains information about the sensed sinusoidal waveform, wherein the sinusoidal waveform has a component of distortion caused at least in part by the magnetic flux created by the current; decompose the received signal to determine the sensed sinusoidal waveform of the magnetic flux caused by the current and a non-sinusoidal magnetic flux waveform of the distortion caused at least in part by the magnetic flux created by the current; compare the non-sinusoidal magnetic flux waveform of the distortion to the baseline non-sinusoidal magnetic flux waveform signature of the motor stored in the memory; and generate a corresponding signal that contains information about the pending failure of the component of the motor based on the comparison of the non-sinusoidal magnetic flux waveform of the distortion to the baseline non-sinusoidal magnetic flux waveform signature stored in the memory.
 34. The system of claim 33, wherein the signal processor is further configured to: determine a pure sinusoidal waveform of a fundamental frequency of the sinusoidal waveform; compare the signal to the pure sinusoidal waveform; and extract the non-sinusoidal magnetic flux waveform of the distortion based on the comparison of the signal to the pure sinusoidal waveform.
 35. The system of claim 34, wherein the signal processor is configured to determine the pure sinusoidal waveform of a fundamental frequency of the sinusoidal waveform by sensing the sinusoidal waveform from a supply voltage of the motor.
 36. The system of claim 33, wherein the signal processor is further configured to: receive another signal from the flux detector during the period of proper operation; extract the non-sinusoidal magnetic flux waveform from the other signal; and store the extracted non-sinusoidal magnetic flux waveform as the baseline non-sinusoidal magnetic flux waveform signature of the motor.
 37. The system of claim 33, wherein the flux detector is a leakage magnetic flux sensor or a current sensor.
 38. The system of claim 33, wherein the signal processor is further configured to determine the pending failure as one or more of a vibration caused by a misalignment, an out of balance condition, one or more failing bearings, a partially shorted winding, a broken rotor bar, an eccentric air gap, or damaged laminations.
 39. The system of claim 33, wherein the signal processor is further configured to perform one or more of an amplification or a spectral analysis of the non-sinusoidal magnetic flux waveform of the distortion.
 40. The system of claim 33, wherein the pending failure is an abnormal condition to cause immediate damage or a potential abnormal condition not to cause immediate damage.
 41. The system of claim 33, wherein the signal processor is further configured to: determine a minimum deviation of the non-sinusoidal magnetic flux waveform of the distortion over time; compare the minimum deviation to a pre-established alarm threshold associated with the pending failure; and include a result of the comparison of the minimum deviation to a pre-established alarm threshold in the corresponding signal.
 42. The system of claim 41, wherein the minimum deviation is a amplitude deviation or a frequency deviation.
 43. A method to detect a pending failure of a component of a motor that drives a pump, the method comprising: sensing, by a flux detector attached to a frame of the motor in relation to a winding of the motor, a sinusoidal waveform of magnetic flux caused by a current that flows in the winding of the motor; receiving, by a signal processor, a signal from the flux detector that contains information about the sensed sinusoidal waveform, wherein the sinusoidal waveform has a component of distortion caused at least in part by the magnetic flux created by the current; decomposing, by the signal processor, the received signal to determine the sensed sinusoidal waveform of the magnetic flux caused by the current and a non-sinusoidal magnetic flux waveform of the distortion caused at least in part by the magnetic flux created by the current; comparing, by the signal processor, the non-sinusoidal magnetic flux waveform of the distortion to a baseline non-sinusoidal magnetic flux waveform signature of the motor stored in a memory; and generating, by the signal processor, a corresponding signal that contains information about the pending failure of the component of the motor based on the comparison of the non-sinusoidal magnetic flux waveform of the distortion to the baseline non-sinusoidal magnetic flux waveform signature stored in the memory.
 44. The method of claim 43, further comprising: determining, by the signal processor, a pure sinusoidal waveform of a fundamental frequency of the sinusoidal waveform by sensing the sinusoidal waveform from a supply voltage of the motor; comparing, by the signal processor, the signal to the pure sinusoidal waveform; and extracting, by the signal processor, the non-sinusoidal magnetic flux waveform of the distortion based on the comparison of the signal to the pure sinusoidal waveform.
 45. The method of claim 43, further comprising: receiving, by the signal processor, another signal from the flux detector during the period of proper operation; extracting, by the signal processor, the non-sinusoidal magnetic flux waveform from the other signal; and storing, by the signal processor, the extracted non-sinusoidal magnetic flux waveform as the baseline non-sinusoidal magnetic flux waveform signature of the motor.
 46. The method of claim 43, further comprising: determining, by the signal processor, the pending failure as an abnormal condition to cause immediate damage or as a potential abnormal condition not to cause immediate damage. 